metals
Article
Application of Optimizing Slab Corner Shapes to Reduce Edge
Seam Defect on Heavy Plates
Minglin Wang 1,2, *, Hui Zhang 1,2, *, Wenbo Zhao 1,2 , Heping Liu 3
Citation: Wang, M.; Zhang, H.; Zhao,
W.; Liu, H.; Wang, X. Application of
Optimizing Slab Corner Shapes to
Reduce Edge Seam Defect on Heavy
Plates. Metals 2022, 12, 1984.
https://doi.org/10.3390/
met12111984
Academic Editors: Miha Kovačič and
Uroš Župerl
Received: 10 October 2022
Accepted: 17 November 2022
Published: 19 November 2022
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Metals 2022, 12, 1984. https://doi.org/10.3390/met12111984
and Xuebing Wang 1,2
1 National Engineering and Research Center of Continuous Casting Technology, Central Iron and Steel
Research Institute, Beijing 100081, China
2 Zhongda National Engineering and Research Center of Continuous Casting Technology Co., Ltd.,
Beijing 100081, China
3 Material Digital R&D Center, China Iron and Steel Research Institute Group, Beijing 100081, China
* Correspondence: wangminglin2005@sina.com (M.W.); zhangh@cisri.com.cn (H.Z.); Tel.:
+86-10-62182665 (M.W.); +86-10-62187142 (H.Z.)
Abstract: The edge seam defect is a common defect in hot rolling heavy plates. It can be improved
by optimizing the corner shapes of slabs. Based on a numerical analysis of the effects of the slab
corner shape on the temperature distribution after the slab’s exit from the heating furnace, three
rolling methods are proposed for controlling the two-chamfered slab corner shape. The stress and
deformation of the corner of the slab during the two-chamfered rolling process are investigated
using a numerical simulation. The results show that a two-chamfered shape slab has the smallest
temperature drop during the cooling process, and the slab corner can maintain higher temperature
and uniformity, which is beneficial for controlling the deformation during the rolling process. Among
the three kinds of two-chamfered rolling methods, frontal rolling using a two-roller has the smallest
rolling force and rolling resistance to the casting machine, followed by horizontal rolling and then
vertical rolling, which has the largest. The favorable slab corner in a two-chamfered shape can be
obtained by frontal rolling using a two-roller. Industrial trials confirm that an edge seam defect rate
of less than 5% in heavy plates can be achieved under the condition of a large broadside ratio.
Keywords: edge seam defect; two-chamfered method; slab corner shape; slab corner temperature;
rolling deformation; numerical simulation
1. Introduction
Edge seam defects or edge black lines, edge warping, etc., are linear defects that appear
on the edge of hot-rolled sheets and plate surfaces. The appearance is similar to the defects
caused by longitudinal cracks on the surface of the slab [1–3]. In the production of strip
steels, low-carbon and ultra-low thin-gauge carbon steel and micro-alloyed high-strength
thick-gauge steel are prone to generate edge seam defects which are 10~20 mm away from
the edge and its depth of 200~400 µm [2–4]. In the production of heavy plates, due to the
application of the broadside rolling process and the small compression ratio, edge seam
defects can occur within a range of about 10 to 60 mm from the edge of the plate, and the
crack depth can reach more than 2.0 mm. The position of the edge seam defect moves
further from the plate edge with the increase of the broadside ratio [5–8]. This defect is
common in major steel companies in the world, and the occurrence rate is as high as 80%.
Figure 1 shows the morphology of three typical edge seam defects on heavy plates.
At present, many metallurgical enterprises usually adopt edge trimming to eliminate
edge seam defects in plates and strips. The trimming amount of one side can reach
17.5 mm for low carbon and ultra-low carbon steels, and 60 mm for heavy plates. The yield
ratio caused by trimming is reduced by about 3%, which brings huge cost losses to the
steel enterprises.
https://www.mdpi.com/journal/metals
 Metals 2022, 12, 1984
022, 12, 1984 2 of 18 2 of 18

(a) (b) (c)

Figure 1. Morphology of edge seam defects on heavy plates. (a) Long edge seam crack; (b) intermit-
tent edge seam crack; (c) reticulated edge seam crack.

At present, many metallurgical enterprises usually adopt edge trimming to eliminate

(a)
edge seam defects in plates and (b) strips. The trimming amount (c) of one side can reach 17.5
mm
Figure 1. Morphology
for low carbon and ultra-low carbon steels, and 60 mm for heavy plates. The yield
Figureof1.edge seam defects
Morphology of edge on heavy plates. on
seam defects (a) heavy
Long edge plates. seam crack;edge
(a) Long (b) intermit-
seam crack; (b) intermit-
ratio
tent edge seam crack; caused by
(c) reticulated trimming
edge is reduced by
seam crack.edge seam crack. about 3%, which brings huge cost losses to the
tent edge seam crack; (c) reticulated
steel enterprises.
At present, many Inthe
In theresearch
researchon
metallurgical on theformation
enterprises
the formationusually mechanism
adopt edge
mechanism ofoftrimming
edgeseam
edge seam cracks,
tocracks,
eliminate someresearchers
some researchers
edge seam defectsbelieve
believe that
in plates defects
and strips.
that defects such
such as Theas longitudinal
trimming cracks
longitudinal amountcracksat of at
theone the
slabsideslab corner,
reach 17.5 corners corners
can transverse
corner, transverse cracks,
mm for low carboncracks,
and surface and surface
and ultra-low
bubbles carbonbubbles
on the slab on the
steels, slab
areandthe 60are
main the main
mmreasons
for heavy reasons for
plates.
for the edge the
The edge
seamyield seam defects
defects on plates on
plates
ratio caused byand trimming and[2,9–12].
strips strips
is reduced[2,9–12]. by Therefore,
Therefore, about in 3%,
order in order
which
to to effectively
brings
effectively huge cost
control control
losses
the the
to occurrence
occurrence the of edgeofseam edge
defects in micro-alloyed steel, some enterprises trim the slab corners off-line after the after
seam
steel enterprises. defects in micro-alloyed steel, some enterprises trim the slab corners off-line slab
isthe
In the research slab
cold, is cold,
onresulting
the resulting
formation
in a huge inwaste
mechanisma huge waste
of of edgeofand
energy energy
seam and resources.
cracks,
resources. some researchers
believe that defectsIn Insuch
recent
recent years,
as years, aalot
longitudinal lotofofresearch
research
cracks atonon
the the
theslabdeformation
corner, transverse
deformation principlecorners
principle ofthe
of theslab slabduring
during thethe
rolling
cracks, and surface
rolling process
bubbles
process and
onandthe thethe formation
slabformation
are the main mechanism
reasons for
mechanism of edge
the edge
of edge seam
seam seam defects
defects
defects has
hason been performed.
been performed.
ItIt is
plates and strips is traditionally
traditionally
[2,9–12]. Therefore, believed
believedin order thattothe
that the temperature
effectively
temperature control decreases relatively
the occurrence
decreases relatively fast
of fast
edgedue due toto the
the two-
two-
dimensional
seam defects indimensional
micro-alloyed heat
heat transfer
transfer
steel, some atenterprises
at the slab
the slab corner,
corner, which
trimwhich
the slab makes
makes the temperature
the
corners temperature
off-line afterdrop drop relatively
relatively
quickly.
the slab is cold,quickly.
resulting The
The transformation
in atransformation
huge waste of from from austenite
energy austenite to ferrite
to
and resources. ferrite occurs
occurs preferentially
preferentially at at the
the corner,
corner,
which results
which aresults
In recent years, lot of in in inconsistent
inconsistent
research deformation
on thedeformation of
deformationofprinciple the metal materials
the metalofmaterialsthe slab in in the slab
the slab
during corner.
thecorner. During During
the
rolling processthe rolling
androlling process,the
process,
the formation thedeformation
deformation
mechanism of edge ofthe
of the
seam corner
cornerdefectsisisrelatively
relatively
has beensmall small andthe
and
performed. thedeformation
deformation
difference
difference
It is traditionally between
believedbetween
that thethe the middleand
middle
temperature and cornerof
corner
decreases ofrelatively
thenarrow
the narrow face
face
fast due ofto
of the
the slab
slab
the two-isislarge,
large,resulting
resulting
dimensional heat inatransfer
in acrease
creaseforming
forming
at the slab atcorner,
at theslab’s
the slab’s narrow
narrow
which makes face.
face.the The
The longitudinal
longitudinal
temperature drop cracks
cracks formedby
formed
relatively bythis
thiskind
kind
of
of crease
crease will
will turn
turn over
over to
to the
the edge
edge of of
thethe wide
wide
quickly. The transformation from austenite to ferrite occurs preferentially at the corner, face,
face, andand eventually
eventually cause
cause the the occurrence
occurrence of
of
edge edge
seam seam defects,
defects, as as
shown shown in in Figure
Figure 2 2 [6,13–17].
[6,13–17].
which results in inconsistent deformation of the metal materials in the slab corner. During
the rolling process, the deformation of the corner is relatively small and the deformation
difference between the middle and corner of the narrow face of the slab is large, resulting
in a crease forming at the slab’s narrow face. The longitudinal cracks formed by this kind
of crease will turn over to the edge of the wide face, and eventually cause the occurrence
of edge seam defects, as shown in Figure 2 [6,13–17].

Figure2.2.Formation
Figure Formationand
andinversion
inversionof
ofedge
edgecreases.
creases.

Hu
Hu[17]
[17]simulated
simulatedrolling
rollingprocess
processononaadefect-free
defect-freeslab.
slab.The
The results
resultsshow
showthat
that whether
whether
rolling
rolling the slab with the original surface or without the original surface, the edge
the slab with the original surface or without the original surface, the edge seam
seam
defects
defectswill
willalways
alwaysbe begenerated.
generated. ThatThat is
is to
to say,
say,the
thegeneration
generationof ofthe
theedge
edgeseam
seamdefects
defectsisis
mainly
mainly related
relatedtotoofthe
the shape,
shape, the
the temperature,
temperature, andand stress
stress characteristics
characteristics of
of the
the slab
slab corners,
corners,
Figure 2. Formation
and and
has inversion
no edge
relationship creases.
with the surface solidification structure of the slab.
and has no relationship with the surface solidification structure of the slab.
Ma et al. [5,18] conducted numerical and physical experimental simulations on the
Hu [17] simulated
formation rolling processof
mechanism onedge
a defect-free slab. The
seam defects on results show that
heavy plates. The whether
simulation results of
rolling the slabright-angle
with the original surface or without the original surface,
slabs show that the edge seam defect occurs during the early the edge seam
broadside-rolling
defects will always be generated.
process. After threeThat is to
passes of say, the generation
broadside of the
rolling, the edgeedge
seamseam defects
defect is
will occur at the front
mainly related and
to the shape, the temperature, and stress characteristics of the slab corners,
end of the slab along the rolling direction. The plate is rotated by 90◦ and rolled in
and has no relationship with the surface solidification structure of the slab.
 front and end of the slab along the rolling direction. The plate is rotated by 90°and rolled
in the longitudinal direction, and the edge seam defect gradually overturns to the inside
of the two wide edges of the plate. The simulation results of the chamfered slab show that
a chamfered slab can reduce the temperature drop and improve the stress state at the slab
corner, so it can effectively prevent the occurrence of the edge seam defect of the plate.
Metals 2022, 12, 1984 The chamfered slab has a great effect on improving the edge seam defect of low 3 ofcar-
18

bon and ultra-low carbon hot strips in the industrial production [18–20]. For the heavy
plates of micro-alloy steel, the chamfered slab greatly reduces the frequency of the occur-
rence
the and depthdirection,
longitudinal of the edge and seam defect.
the edge However,
seam once the edge
defect gradually seam defect
overturns to the occurs
inside ofon
the two wide
a heavy plateedges
rolledofby thea plate.
chamferedThe simulation results ofofthe
slab, the position thechamfered
defect willslab show that
be closer a
to the
chamfered slab than
inside of plate can reduce
when itthe temperature
is rolled drop and improve
by the right-angle the stress
slab caused by thestate at the slab
broadside-roll-
corner, so it can
ing process. effectively
Instead, prevent the
the trimming occurrence
amount of the edge
is occasionally seam defect of the plate.
increased.
The chamfered slab has a great effect on improving
In order to effectively eliminate the occurrence of edge seam the edge seam defect
defects onofheavy
low carbon
plates,
and ultra-low carbon hot strips in the industrial production
a numerical simulation and industrial production verification were carried out on the[18–20]. For the heavy plates
cor-
of micro-alloy
ner-rolling steel,of
process thethechamfered
one-chamfer slabslab
greatly
under reduces the frequency
three rolling modes. The of the occurrence
optimal rolling
and depthtoofobtain
method the edge seam defect.
a reasonable cornerHowever,
shape ofonce
thethe edge seam defect
two-chamfered slab occurs on a heavy
is proposed.
plate rolled by a chamfered slab, the position of the defect will be closer to the inside of
plate than when
2. Materials anditMethods
is rolled by the right-angle slab caused by the broadside-rolling process.
Instead, the trimming
2.1. Industrial Trial Process amount is occasionally
for Optimizing Slab increased.
Corner Shape
In order to effectively eliminate the occurrence of edge seam defects on heavy plates,
At present,
a numerical there are
simulation andthree process methods
industrial production thatverification
have been developed
were carried andout applied
on the to
optimize the slab corner shape:
corner-rolling process of the one-chamfer slab under three rolling modes. The optimal
(1) Horizontal
rolling method torolling:
obtain aThe roller for
reasonable the chamfered
corner shape of theslab corner is one
two-chamfered roller
slab which is
is proposed.
placed on the left and right sides of the slab as shown in Figure 3. The top and bottom
2. Materials
ends ofand Methods
the roller are provided with wheel rims, and the inclination and shape of the
2.1. Industrial
wheel rims Trialare
Process for Optimizing
the same Slab Corner
as the expected shape Shape
of the slab corner after rolling. The
hydraulic
At present,cylinder
there arepushes the roller
three process in a horizontal
methods that havedirection and applies
been developed and pressure
applied to to
the slab corner through
optimize the slab corner shape: the wheel rim, so that the expected deformation of the slab
corner is obtained. For the convenience of maintenance, the device is placed at the
(1) Horizontal rolling: The roller for the chamfered slab corner is one roller which is
outlet of the secondary cooling chamber of the continuous casting machine.
placed on the left and right sides of the slab as shown in Figure 3. The top and bottom
This method
ends is characterized
of the roller are providedby its simple
with structure
wheel rims, and and convenientand
the inclination implementation.
shape of the
It canwheel
be applied
rims areto rolling
the same slabsas with the sameshape
the expected thickness and
of the different
slab cornerwidths. The rollers
after rolling. The
needhydraulic
to be replaced
cylinder pushes the roller in a horizontal direction and applies pressure tois
when the slab thickness changes. The disadvantage of the structure
that the rolling forcethrough
slab corner of the rollerthe onwheelthe slab
rim, is
soathat
lateral
theextrusion
expectedforce since theof
deformation roll rotates
the slab
horizontally,
corner is and the force
obtained. Forand the deformation
convenience of the slab are unreasonable.
maintenance, the device isThe placedbulges on
at the
the top andofbottom
outlet surfacescooling
the secondary of the slab are easy
chamber to form.
of the continuous casting machine.

Figure3.3.Schematic
Figure Schematicdiagram
diagramof
ofhorizontal
horizontalrolling
rollingatatthe
thechamfered
chamferedslab
slabcorner.
corner.

This method is characterized by its simple structure and convenient implementation.

It can be applied to rolling slabs with the same thickness and different widths. The rollers
need to be replaced when the slab thickness changes. The disadvantage of the structure is
that the rolling force of the roller on the slab is a lateral extrusion force since the roll rotates
horizontally, and the force and deformation of the slab are unreasonable. The bulges on the
top and bottom surfaces of the slab are easy to form.
(2) Vertical rolling: The rolls for vertical rolling at the chamfered slab corners are placed
on the inner and outer arcs of the slab, as shown in Figure 4, in contrast with horizontal
rolling. It rolls the slab corner using the wheel rim. This rolling method can use the
backup rolls in the existing segment of the continuous casting machine to increase
the wheel rim to meet the need of rolling. It is suitable for the optimal deformation
of slab corners with the same width and different thicknesses. If the width of the
slab changes during the production process, it is necessary to adjust the position of
 (2) Vertical rolling: The rolls for vertical rolling at the chamfered slab corners are placed
on the inner and outer arcs of the slab, as shown in Figure 4, in contrast with hori-
zontal rolling. It rolls the slab corner using the wheel rim. This rolling method can
use the backup rolls in the existing segment of the continuous casting machine to
increase the wheel rim to meet the need of rolling. It is suitable for the optimal defor-
Metals 2022, 12, 1984 4 of 18
Metals 2022, 12, 1984 mation of slab corners with the same width and different thicknesses. If the width 4 of 18of
the slab changes during the production process, it is necessary to adjust the position
of the wheel rims or replace the roll. The operation is more complicated, especially
the
the wheel rimsoforreplacing
operation replace the theroll. The
outer arcoperation
roll. is more complicated, especially the
(2) Vertical
operation rolling: The rolls
of replacing thefor vertical
outer rolling at the chamfered slab corners are placed
arc roll.
(3) on the inner
Frontal and
rolling outer
using arcs of the The
a two-roller: slab,frontal
as shown in using
rolling Figuretwo-roller
4, in contrast with hori-
equipment was
zontal rolling.
developed It rollstothe
in order slab corner
overcome using the wheel
the disadvantages of rim. This rolling
horizontal rollingmethod can
on the slab
use the deformation
corner backup rollsasinshown the existing segment
in Figure of thethe
5. Although continuous casting
rolling force is alsomachine
generated to
increase the wheel
on the slab cornerrimfrom to meet the need of
the horizontal rolling. Itthe
direction, is suitable for the optimal
rolling surface defor-
of the roller is
mation of slab corners with the same width and different thicknesses.
approximately perpendicular to the bisector of the slab corner. The slab corner is If the width of
the slab changes
subjected during
to positive the production
pressure during the process, it is
rolling necessary
process. to adjust
Thereby, thethe position
stress state
of
ofthe
thewheel rims orcan
slab corners replace the roll. The
be improved, andoperation is more
the occurrence of complicated, especially
bulges and defects can
the operation of replacing the outer arc roll.
be reduced.

Figure 4. Schematic diagram of vertical rolling at the chamfered slab corner.

(3) Frontal rolling using a two-roller: The frontal rolling using two-roller equipment was
developed in order to overcome the disadvantages of horizontal rolling on the slab
corner deformation as shown in Figure 5. Although the rolling force is also generated
on the slab corner from the horizontal direction, the rolling surface of the roller is
approximately perpendicular to the bisector of the slab corner. The slab corner is sub-
jected to positive pressure during the rolling process. Thereby, the stress state of the
slab corners can be improved, and the occurrence of bulges and defects can be re-
Figure 4.
4. Schematic
Schematic diagram
Figureduced. diagram of
of vertical
vertical rolling
rolling at
at the
the chamfered
chamfered slab
slab corner.
corner.

(3) Frontal rolling using a two-roller: The frontal rolling using two-roller equipment was
developed in order to overcome the disadvantages of horizontal rolling on the slab
corner deformation as shown in Figure 5. Although the rolling force is also generated
on the slab corner from the horizontal direction, the rolling surface of the roller is
approximately perpendicular to the bisector of the slab corner. The slab corner is sub-
jected to positive pressure during the rolling process. Thereby, the stress state of the
slab corners can be improved, and the occurrence of bulges and defects can be re-
duced.

Figure5.5.Schematic
Figure Schematicdiagram
diagramofoffrontal
frontalrolling
rollingusing
usingaatwo-roller
two-rolleratatthe
thechamfered
chamferedslab
slabcorner.
corner.

2.2.
2.2.Numerical
NumericalSimulation,
Simulation,Methods,
Methods,and andConditions
Conditions
2.2.1. Numerical Simulation of the Temperature Distribution of Different Slab
2.2.1. Numerical
Corner Shapes Simulation of the Temperature Distribution of Different Slab Corner
Shapes
In order to analyze the influence of shapes on the temperature reduction of the slab cor-
Inslab
ner, the order to analyzedistribution
temperature the influence of of shapes
four kindson of the temperature
corner shapes of 260reduction
mm × of themm
1650 slab
corner, the slab temperature distribution of four kinds of corner
slab of Q345 B were simulated using a developed heat-conduction model with considera- shapes of 260 mm × 1650
mmofslab
tion the of
airQ345 B were
radiation simulated
based using
on a finite a developed
volume method (FVM)heat-conduction
according tomodel
ANSYS with con-
Fluent
sideration
Figure
2020 ® 5. of theThe
Schematic
software. air conduction
radiation
diagram based
of frontal on transfer
ofrolling
heat ausing
finitea volume
two-rollermethod
in the slabat is
the (FVM) according
chamfered
described by slab to AN-
thecorner.
following
SYS Fluent
transient 2020equation:
energy
® software. The conduction of heat transfer in the slab is described by the

following
2.2. Numericaltransient energy
Simulation, equation:
Methods, and Conditions
    
∂T s ∂ ∂Ts ∂ Distribution
∂Ts ∂ of Different
∂Ts .
2.2.1. NumericalρSimulation
s C p,s = of the
ks Temperature
+ ks + ks + qSlab Corner (1)
Shapes ∂t ∂x ∂x ∂y ∂y ∂z ∂z
In ρorder to analyze the influence
−3 of shapes on the temperature reduction◦ of the slab
where s is the density (kg·m ), Cp,s is the specific heat capacity J/(kg C), ks is the heat
corner, the slab temperature
− 1 − 1 distribution of four kinds of corner .
shapes of 260 mm × 1650
conductivity (W·m ·K ), Ts is the temperature of the slab (K), q is the internal heat
mm slab of rate
generation Q345per
B were simulated
unit volume, using
t is a developed
the time (s), x, y, heat-conduction model
z is the slab width (m), with con-
thickness
sideration of the air direction,
(m) and length(m) radiation based on a finite
respectively. volume method
Conduction (FVM) according
in the direction that theto AN-
slab is
SYS Fluent 2020® software. The conduction of heat transfer in the slab is described by the
following transient energy equation:
 𝜕𝑇𝑠 𝜕 𝜕𝑇𝑠 𝜕 𝜕𝑇𝑠 𝜕 𝜕𝑇𝑠
𝜌𝑠 𝐶𝑝,𝑠 = (𝑘 )+ (𝑘 ) + (𝑘𝑠 ) + 𝑞̇ (1)
𝜕𝑡 𝜕𝑥 𝑠 𝜕𝑥 𝜕𝑦 𝑠 𝜕𝑦 𝜕𝑧 𝜕𝑧
where 𝜌𝑠 is the density (kg·m−3), 𝐶𝑝,𝑠 is the specific heat capacity J/(kg.°C), 𝑘𝑠 is the heat
Metals 2022, 12, 1984
conductivity (W·m−1·K−1), 𝑇𝑠 is the temperature of the slab (K), 𝑞̇ is the internal heat 5gen-
of 18
eration rate per unit volume, 𝑡 is the time (s), 𝑥, 𝑦, 𝑧 is the slab width (m), thickness (m)
and length(m) direction, respectively. Conduction in the direction that the slab is moving
along the rolling direction is ignored. The boundary condition of heat radiation by air-
movingisalong
cooling giventhe
by:rolling direction is ignored. The boundary condition of heat radiation by
air-cooling is given by:  4 4
qs𝑞=𝑠 =
σε𝜎𝜀(𝑇
Ts 4𝑠 −−T𝑇∞∞4 ) (2)
(2)
where 𝜎 is the Stefan Boltzman constant (5.67 × 10−8−W· m−2·K−4 ) and 𝜀 is the emissivity of
where σ is the Stefan Boltzman constant (5.67 × 10 8 W·m−2 ·K−4 ) and ε is the emissivity
the slab surface, selected as 0.80, and 𝑇∞ are the surrounding temperatures in the air cool-
of the slab surface, selected as 0.80, and T∞ are the surrounding temperatures in the air
ing (K).
cooling (K).
The initial slab temperature is set as 1150 ℃ after leaving the heating furnace and air
The initial slab temperature is set as 1150 °C after leaving the heating furnace and
cooling for 10 min. The four kinds of corner shapes are a right-angle slab (RS), a one-
air cooling for 10 min. The four kinds of corner shapes are a right-angle slab (RS), a one-
chamfered slab (OCS), a small two-chamfered slab (STCS), and a large two-chamfered
chamfered slab (OCS), a small two-chamfered slab (STCS), and a large two-chamfered
slab (LTCS). The chamfered length is 55 mm and the chamfered angle is 30°◦for the one-
slab (LTCS). The chamfered length is 55 mm and the chamfered angle is 30 for the one-
chamfered slab. The angles of the two-chamfered slab are 30°◦ and 60°,◦ respectively. The
chamfered slab. The angles of the two-chamfered slab are 30 and 60 , respectively. The
two-chamfered lengths of the STCS are 17 mm and 45.2 mm, respectively, and the two-
two-chamfered lengths of the STCS are 17 mm and 45.2 mm, respectively, and the two-
chamfered
chamferedlengths
lengthsof ofthe
theLTCS
LTCS are
are about
about 35
35 mm.
mm. The
Thegeometrical
geometricaldimensions
dimensionsofofthe
thefour
four
corner
cornershapes
shapesslab
slabare
are260
260 mm
mm ××1650
1650mmmmwhich
whichare
areshown
shownininFigure
Figure6.6.

Figure
Figure6.6.The
Thegeometrical
geometricaldimensions
dimensionsof
offour
fourcorner-shape
corner-shapeslabs:
slabs:(a)
(a)RS;
RS;(b)
(b)OCS;
OCS;(c)
(c)STCS;
STCS;(d)
(d)LTCS.
LTCS.

2.2.2. Numerical Simulation of Two-Chamfered Rolling Process

2.2.2. Numerical Simulation of Two-Chamfered Rolling Process
(1) Mathematical model
(1) Mathematical model
Inindustrial
In industrialproduction,
production,the thetwo-chamfered
two-chamferedequipment
equipmentof ofthe
theslab
slabisisarranged
arrangedat atthe
the
outletof
outlet of the
the continuous
continuous casting
casting machine.
machine. DueDuetotothe
thenarrow
narrowspace
spaceat atthis
this position,
position, the
the
equipment is
equipment is not
not installed
installed with
withaatransmission
transmissionsystem
systemininorder
order to to
simplify
simplify it. That is toissay,
it. That to
the rolling
say, resistance
the rolling caused
resistance by the
caused byslab
the corner rolling
slab corner of theoftwo-chamfered
rolling the two-chamfered equipment
equip-is
borneisby
ment the existing
borne transmission
by the existing force of the
transmission caster.
force Therefore,
of the it is necessary
caster. Therefore, it is to investigate
necessary to
investigate the rolling force and rolling resistance during the rolling process for slabs.
the rolling force and rolling resistance during the rolling process for two-chamfered two-
In thisslabs.
chamfered study, a developed thermo-mechanical FEM mathematic model based on a
general finite element
In this study, a developed ABAQUS® 2020 byFEM
package ofthermo-mechanical Dassault Systèmesmodel
mathematic is usedbasedto analyze
on a
the casting–rolling
general finite element deformation
package ofunderABAQUSdifferent rolling
® 2020 methods.
by Dassault The 3D transient
Systèmes is used to energy
ana-
balance equation for the rolling slab is used. Sequentially coupled
lyze the casting–rolling deformation under different rolling methods. The 3D transient thermomechanical
analysis
energy is implemented
balance equation forin the
the rolling
mechanical
slab ismodel. The isotropic
used. Sequentially Hooke’s
coupled law is used to
thermomechan-
model the elastic strain and the thermal expansion coefficient
ical analysis is implemented in the mechanical model. The isotropic Hooke’s law adopted for the thermal
is used
strain. The plastic strain is computed by enforcing the von Mises yield
to model the elastic strain and the thermal expansion coefficient adopted for the thermal criterion and the
classic Prandtl–Reuss flow rule [21]:
strain. The plastic strain is computed by enforcing the von Mises yield criterion and the
classic Prandtl–Reuss flow rule: [21] p
dε ij = dε ij + dεeij (3)

p
dε ij = dλσij0 (4)
1 1 − 2µ
dσij0 +
dεeij = dσm δij (5)
2G E
where superscripts e and p are used to denote the elastic increment and the plastic strain
increment, respectively, E is the Young’s modulus, µ is the Poisson’s ratio, G is the elastic
 𝑝 𝑝
𝑒 𝑒
𝑑𝜀𝑖𝑗𝑑𝜀 =𝑖𝑗𝑑𝜀
=𝑖𝑗𝑑𝜀 +𝑖𝑗𝑑𝜀+𝑖𝑗𝑑𝜀𝑖𝑗 (3) (3)
𝑝 𝑝 , ,
𝑑𝜀𝑖𝑗𝑑𝜀 = 𝑑𝜆𝜎
=𝑖𝑗𝑑𝜆𝜎𝑖𝑗 𝑖𝑗 (4) (4)

Metals 2022, 12, 1984 𝑒 𝑒

1 1 , ,1 − 12𝜇− 2𝜇 6 of 18
𝑑𝜀𝑖𝑗𝑑𝜀
=𝑖𝑗 = 𝑑𝜎 𝑑𝜎
+ + 𝑑𝜎 𝑑𝜎
𝛿 𝛿 (5) (5)
2𝐺 2𝐺𝑖𝑗 𝑖𝑗 𝐸 𝐸 𝑚 𝑖𝑗𝑚 𝑖𝑗
where
where superscripts
superscripts 𝑒 and𝑒 and 𝑝are𝑝areused used to denote
to denote the the elastic
elastic increment
increment andand
the the plastic
plastic strain
strain
increment,
increment, respectively,
respectively, 𝐸 𝐸
is is
the the Young’s
Young’s 0
modulus,
modulus, 𝜇 is𝜇
shear modulus, dλ is a non-negative factor, σij is the deviatoric stress tensor, and δij isisthe
is
the the Poisson’s
Poisson’s 𝐺
ratio,
ratio, 𝐺
is the the
, ,
elastic
elastic shearshear modulus,
modulus,
Kronecker symbol. 𝑑𝜆 𝑑𝜆
is a is a non-negative
non-negative factor, 𝜎
factor, 𝜎
𝑖𝑗 𝑖𝑗is is
the the deviatoric
deviatoric stress
stress tensor,
tensor, and and
𝛿𝑖𝑗 𝛿is𝑖𝑗the
is the Kronecker
Kronecker symbol.
symbol.
(2) Geometry and mesh
(2) (2) Geometry
Geometry andand
mesh mesh
In In Inorder
order to to
order tosimplify
simplify thethe
simplify the calculation,
calculation,
calculation, 1/41/4
1/4 chamfered
chamfered
chamfered slabslab
slab
was was
was adopted.
adopted.
adopted. TheThe
The original
original
original
section
section
section size
sizesize of the
of the
of the Q345B
Q345BQ345B slab
slabslab is
is 260 260
is 260mm
mmmm × 1650
× 1650
× 1650 mmmmmm with
withwith 55 mm55 mm
55 mm chamfered
chamfered
chamfered length
length
length andand
and
30 ◦ chamfered angle, and the casting speed is 0.85 m/min. Figure 7 shows the geometric
30° 30° chamfered
chamfered angle,
angle, andandthe the casting
casting speedspeed is 0.85
is 0.85 m/min.m/min. FigureFigure 7 shows
7 shows the the geometric
geometric
models
models
models andand
and mesh
meshmesh systems
systems
systems forforfor three
threethree different
different
different rolling
rolling
rolling methods.
methods.
methods. TheThe
The rollers
areare
rollers
rollers are treatedas as
treated
treated as
isothermal
isothermal
isothermal analytical
analytical
analytical rigid
rigid
rigid bodies.
bodies.
bodies. The
TheThe slab is
slabslab treated
is treated
is treated as a deformable
as aasdeformable
a deformablebody
body and
body discretized
andand discre-
discre-
by
tized
tized thethe
by coupled
by the
coupledthermo-mechanical
coupled thermo-mechanical
thermo-mechanical hexahedron element
hexahedron
hexahedron with
element
element witheight
with nodes
eight
eight (C3D8RT).
nodes
nodes (C3D8RT).
(C3D8RT).

(a) (a) (b) (b) (c) (c)

Figure
Figure 7. 7.
Figure 7.The
The The
modelmodel
model of different
ofofdifferent
different rolling
rolling
rolling methods.
methods.
methods. (a) Horizontal
(a)Horizontal
(a) Horizontal rolling;
rolling;
rolling; (b)(b) (b) vertical
vertical
vertical rolling;
rolling;
rolling; (c) (c)
(c) frontal
frontal
frontal rolling
rolling
rolling using usingusing a two-roller.
a two-roller.
a two-roller.

FigureFigure
Figure 8 8isais
8 is a partial
apartial
partial enlarged
enlarged
enlarged view view ofone-chamfered
a one-chamfered
ofaaone-chamfered
of slab
slab slab meshing
meshing
meshing before
before before defor-
defor-
deformation.
mation.
mation.
In In it,Innodes
it, nodes it,
A,nodes
B, A,
C, B,A,C,B,D
and C,onand
and DtheonDslab’s
on the
the slab’s
slab’s
wide widewide
face, andface,
face, and and
nodes a,nodes
nodes b,a,c,b,a,c,b,and
and dc,on
andond the
dthe on the
slab’s
slab’s
slab’s
chamfered chamfered
chamfered facefaceareface
are are particularly
particularly
particularly selected
selected
selected for for analyzing
analyzing
for analyzing the the deformation
deformation
the deformation behaviors
behaviors
behaviors under
under
under
different different
different rolling
rolling rolling
methods. methods.
methods. Among
Among Among
them,them,them, node-A
node-A
node-A is the
is the
is the closest
closest
closest to to to
thethe the two-chamfered
two-chamfered
two-chamfered face
faceface
on ontheonwide
the the
wide wide
face,face,face,
and
and and nodes
nodes
nodes B, B,
C,C,B,and
and C,Dand
D D
areare
oneare
one one
nodenode node length
length
length awayawayaway
fromfrom from node-A,
node-A,
node-A, in in
turn.in
Similarly,
turn.
turn. Similarly, node-a
Similarly,node-a is the
node-a closest
is the
is the to the
closest
closest two-chamfered
to theto the
two-chamfered faceface
two-chamfered onface
the slope,
on the
on the and
slope,slope,nodes
and and b,nodes
nodes c,b,andb,
dc,are,
c, and and indturn,
d are, are, one
in
in turn, node
turn,
one one length
node node away
lengthlength from
away away node-a.
from from node-a.
node-a.

Figure
Figure
Figure 8.8.Enlarged
Enlarged
8. Enlarged viewview and
andand
view theselected
thethe selected
selected nodes
nodes along
along
nodes theslab
thethe
along slabslab corner
corner before
before
corner deformation.
deformation.
before deformation.

(3) Boundary conditions and material properties

The contact conditions at the interfaces between the slab and the rollers were described
using the Coulomb friction model. A translational velocity of 0.85 m/min along the pulling
direction is applied on the slab of the inflow region and is to be identical to the opposite
movement of the rotating roller in a real manufacture. The displacement vector components
perpendicular to the symmetric planes of XZ and YZ are zero. It should be noted that the
total rolling force acting on the corner of the slab is defined as the sum of elastic and plastic
deformation zones, obtained from the reaction forces (RF) components in ABAQUS® 2020
by Dassault Systèmes. The rolling resistance is extracted as the negative RF components of
the roller interaction on the slab.
Metals 2022, 12, 1984 7 of 18

A medium carbon micro-alloyed steel of grade Q345B with a chemical composition

given in percent mass of 0.16C-0.52Si-1.53Mn-0.024P-0.0023S-0.021Al-0.027Nb-0.0039Ti is
investigated. A constitutive model for metals of the Johnson–Cook model [22], which con-
siders independently the effects of strain hardening, strain rate hardening, and temperature
softening on flow stress, is used to predict the mechanical behaviors of the Q345B materials:
.∗
 
σ = ( A + Bεn ) 1 + Clnε (1 − T ∗m ) (6)

.∗
where σ is equivalent stress, ε is equivalent plastic strain, ε is dimensionless strain rate,
T ∗m = ( T − 298)/( Tmelt − 298) is homologous temperature, T is current temperature, and
Tmelt is metal melting temperature. Constants A, B, C, m, and n are material parameters.
Constant A is a yield stress at a user-defined reference temperature and reference strain rate.
Constants B and n are strain-hardening parameters. Constant C is a strain-rate-hardening
parameter. Constant m is a temperature-softening parameter.
The value of A is calculated from the yield stress of the flow curve at 1173 K and 1 s−1
with the strain rate at 0.002. B and n are calculated from Equation (7), using the flow stress
data at various strain rates for the same flow curves.

σ = A + Bεn (7)
.∗
The value of C can be obtained from the slop of the [σ/( A + Bε 0 n ) − 1] vs. lnε plot,
using the flow stress data for a fixed strain at the reference temperature and different
strain rates.
.∗
σ/( A + Bε 0 n ) − 1 = Clnε (8)
The material constant m is obtained from the plot of ln[1 − (σ/A + Bε 0 )] vs. lnT ∗
using the flow curves at different temperatures at the reference strain rate.

ln[1 − (σ/A + Bε 0 )] = mlnT ∗ (9)

The material constants of the Johnson–Cook model are crucial for an accurate predic-
tion of casting-rolling stress and deformation in the rolling process. All of these material
parameters are determined here based on the thermo-simulation data during a hot com-
pression deformation process in our previous work [23]. The constants A, B, n, C and m
used in this study are: A = 43 MPa, B = 166.86 MPa, n = 0.3163, C = 0.1123, m = 0.8484.
The effectiveness of the material parameters in hot-rolling calculations has been validated
in [23].
The physical property data of Q345B (specific heat, thermal conductivity, Young’s
modulus, and thermal expansion coefficient) and their variation at the temperatures used
in the present study in Section 2.2.1 and Section 2.2.2 are shown in Figure 9.
Metals
Metals2022, 12,12,
2022, 1984
1984 88ofof1818

(a) (b)

(c) (d)
Figure
Figure 9. 9.
TheThe physical
physical property
property data data of Q345B.
of Q345B. (a) Specific
(a) Specific heat; (b)heat; (b) conductivity;
thermal thermal conductivity;
(c) Young’s(c)
Young’s modulus; (d) thermal expansion
modulus; (d) thermal expansion coefficient. coefficient.

3.3.Results
Results
3.1.
3.1.Influence
InfluenceofofSlab
SlabCorner
CornerShape
ShapeononTemperature
Temperature
Figure
Figure1010shows
showsthe
thepredicted
predictedcorner
cornertemperature
temperatureofofa aslabslabwith
withdifferent
differentcorner
corner
shapes.
shapes. It can be seen that the center temperature of the four kinds of slabsisisalmost
It can be seen that the center temperature of the four kinds of slabs almostthe
the
same. However, there is a great difference between the corner temperatures
same. However, there is a great difference between the corner temperatures of the four of the four
kinds
kindsofofslab.
slab.The
Thecorner
cornertemperature
temperatureofofthe
theright-angle
right-angleslab
slabisis855
855°C,
℃,which
whichisisrelated
relatedtoto
the
the two-dimensional cooling of the right-angle slab. The angle between the slopeand
two-dimensional cooling of the right-angle slab. The angle between the slope andthethe
narrow face (narrow-face angle) of the one-chamfered slab is 150◦ , the angle between the
narrow face (narrow-face angle) of the one-chamfered slab is 150°, the angle between the
slope and the wide face (wide-face angle) is 120◦ , and the temperature of the smaller angle
slope and the wide face (wide-face angle) is 120°, and the temperature of the smaller angle
is also lower, at 910 ◦ C. Each of the three corners of the slab with the two-chamfered shape
is also lower, at 910 °C. Each of the three corners of the slab with the two-chamfered shape
is 150◦ or close to 150◦ , so it is closer to one-dimensional cooling. The lowest temperature
is 150° or close to 150°, so it is closer to one-dimensional cooling. The lowest temperature
is on the intersection angle of the two-chamfered faces. The lowest corner temperatures of
is on the intersection angle of the two-chamfered faces. The lowest corner temperatures of
the small two-chamfered and large two-chamfered slab are 926 ◦ C and 933 ◦ C, respectively.
the small two-chamfered and large two-chamfered slab are 926 °C and 933 °C, respec-
The temperature of the two-chamfered slab corner is higher compared with the right-angle
tively. The temperature of the two-chamfered slab corner is higher compared with the
slab and the one-chamfered slab, which establishes a good foundation for fundamentally
right-angle slab and the one-chamfered slab, which establishes a good foundation for fun-
eliminating the edge seam defect.
damentally eliminating the edge seam defect.
Metals2022,
Metals 12,1984
2022,12, 1984 9 9ofof18
18

(a) (b)

(c) (d)
Figure
Figure10.
10.Temperature
Temperaturedistribution
distributionof
ofslab
slabcorners
cornersofofdifferent
differentshapes.
shapes.(a)
(a)Right-angle
Right-angleslab;
slab;(b)
(b)one-
one-
chamfered slab; (c) small two-chamfered slab; (d) large two-chamfered
chamfered slab; (c) small two-chamfered slab; (d) large two-chamfered slab. slab.

Figure
Figure11 11 shows
shows thethe temperature
temperaturechange changetrend
trendofofa aslab
slab surface
surface along
along thethe slab
slab thick-
thickness,
ness,
in theindirection
the direction
fromfrom the the center
center to the to the slab’s
slab’s narrow
narrow side.ItItcan
side. canbebe seen
seen that:
that: (1)
(1) The
The
temperature of various shapes of slabs shows a slow decrease
temperature of various shapes of slabs shows a slow decrease and is basically the same and is basically the same
within
withinthe therange
rangeof ofabout
about82.4
82.4mm mmfrom fromthe thecenter
centerof ofthe
thenarrow
narrowface.face.The
Theright-angle
right-angleslabslab
isisslightly
slightlyhigher
higherdue duetotothe
theone-dimensional
one-dimensionalcooling coolingin inthe
thezone
zonefar farfrom
fromthe thecorner.
corner.TheThe
temperature
temperature of the the right-angle
right-angleslab slabdecreases
decreases notably
notably withwiththethe increase
increase of distance
of the the distance
from
from the narrow
the narrow side’s side’s
center,center,
and theand the temperature
temperature begins tobegins
be lowerto be lower
than that than
of thethat of the
chamfered
chamfered
slab. (2) The slab. (2)chamfered
first The first chamfered
slope occurs slope occurs
within thewithin
range the range
of 82.4 mm of to
82.4 mmmm
112.2 to 112.2
from
mm from the
the center of center of theface.
the narrow narrow face.time,
At this At this
thetime, the temperature
temperature difference difference
is small is small
because
because the one-chamfered
the one-chamfered slab and slabtheand the two-chamfered
two-chamfered slabs have
slabs have the same
the same slopeslope
shape.shape.
The
temperature
The temperature curve first first
curve appears platform
appears due to
platform duethetochamfering
the chamferingshape shape
and thenandslowly
then
decreases.
slowly (3) With
decreases. (3) the
With appearance
the appearance of theoftwo-chamfered
the two-chamfered slope, the two-chamfered
slope, the two-chamfered slab
corner
slab temperature
corner temperature begins to rise,
begins towhich increases
rise, which the temperature
increases difference
the temperature betweenbe-
difference the
two-chamfered
tween slab and slab
the two-chamfered the one-chamfered
and the one-chamfered slab. The large
slab. Thetwo-chamfered
large two-chamfered slab corner
slab
temperature
corner is higher
temperature than the
is higher thansmall two-chamfered
the small two-chamfered slab because the chamfering
slab because the chamferingslope
length of the large two-chamfered slab
slope length of the large two-chamfered slab is greater. is greater.
To sum up, the corner temperature of the large two-chamfered slab is the highest, the
small two-chamfered slab comes second, third is the one-chamfered slab, and the right-
angle slab is the lowest. The two-chamfered slab is beneficial to controlling the edge seam
defect during the rolling process.
Metals 2022, 12, 1984 10 of 18
Metals 2022, 12, 1984 10 of 18

(a) (b)
Figure 11. Temperature
Figure distribution
11. Temperature at different
distribution heights
at different fromfrom
heights the narrow face’sface’s
the narrow centercenter
of various
of various
shape slabs. (a) Temperature distribution; (b) point designation diagram.
shape slabs. (a) Temperature distribution; (b) point designation diagram.

3.2. Effects
To of
sumRolling
up, Methods on temperature
the corner Slab Corner Deformation
of the large two-chamfered slab is the highest,
3.2.1. The Rolling Force of Two-Chamfered Rollingthird is the one-chamfered slab, and the
the small two-chamfered slab comes second,
right-angle slab is the lowest. The two-chamfered slab is beneficial to controlling the edge
The two-chamfered slope is rolled at an angle of 30° to the slab’s wide face. The length
seam defect during the rolling process.
of the two-chamfered slope obtained by rolling is 11 mm, 14 mm, 17 mm, and 20 mm. For
industrial production,
3.2. Effects of Rolling the hydraulic
Methods on Slabcylinder is used to drive the two-chamfered roller.
Corner Deformation
The3.2.1.
diameter of the hydraulic cylinder is 250
The Rolling Force of Two-Chamfered Rolling mm. The rolling force will increase by about
0.5 ton for every 1 MPa pressure increase. When the length of the two-chamfered length
The two-chamfered slope is rolled at an angle of 30◦ to the slab’s wide face. The length
is 20 mm, the hydraulic cylinder pressure is about 100 MPa. The increasing of the two-
of the two-chamfered slope obtained by rolling is 11 mm, 14 mm, 17 mm, and 20 mm. For
chamfered length will not only increase the rolling force greatly, but also cause the unrea-
industrial production, the hydraulic cylinder is used to drive the two-chamfered roller. The
sonable slab corner deformation due to the metal flow.
diameter of the hydraulic cylinder is 250 mm. The rolling force will increase by about 0.5 ton
The required rolling force of the two-chamfered slab under various rolling methods
for every 1 MPa pressure increase. When the length of the two-chamfered length is 20 mm,
is listed in Table 1. As can be seen from the Table 1, the rolling force required for the two-
the hydraulic cylinder pressure is about 100 MPa. The increasing of the two- chamfered
chamfered rolling by frontal rolling using a two-roller is the smallest among the three
length will not only increase the rolling force greatly, but also cause the unreasonable slab
rolling methods, followed by horizontal rolling, then vertical rolling, which is the largest.
corner deformation due to the metal flow.
This is due to the different amount of metal deformation under the three rolling methods.
The required rolling force of the two-chamfered slab under various rolling methods
is listed in Table 1. As can be seen from the Table 1, the rolling force required for the
Table 1. Required rolling force for different rolling methods. (ton).
two-chamfered rolling by frontal rolling using a two-roller is the smallest among the three
rolling methods,Chamfered
followed Length
by horizontal
(mm) rolling, then vertical rolling, which is the largest.
11 14 17 20
This is dueRolling Methods amount of metal deformation under the three rolling methods.
to the different
Horizontal rolling 20.8 31.3 43.1 53.2
Vertical
Table 1. Required rolling
rolling 21.8
force for different rolling 32.8
methods. (ton). 45.3 54.0
Frontal rolling using a two-roller 18.6 29.6 40.4 48.6
Chamfered Length (mm)
11 14 17 20
3.2.2.Rolling
RollingMethods
Resistance for the Two-Chamfered Method
Horizontal
The rolling rolling
resistance for two-chamfered20.8 31.3
rolling refers 43.1
to the counterforce 53.2
against the
Vertical rolling 21.8 32.8 45.3
drawing direction caused by the rolling process. The rolling resistance of the four corners 54.0
Frontal rolling using a two-roller 18.6 29.6 40.4 48.6
of the slab under different rolling methods is shown in Table 2. The rolling resistance of
frontal rolling using the two-roller is the smallest among the three rolling methods, fol-
3.2.2.byRolling
lowed Resistance
horizontal rolling,forthen
the Two-Chamfered Method
vertical rolling, which is the largest. This follows the
same order as the rolling
The rolling force,
resistance for and the rolling rolling
two-chamfered resistance difference
refers for variousagainst
to the counterforce rollingthe
methods
drawing is direction
very small. The by
caused rolling resistance
the rolling increases
process. with resistance
The rolling the two-chamfered
of the four length.
corners of
Thethe
excessive
slab underrolling resistance
different rollingwill directly
methods affect the
is shown stable2.and
in Table Thesmooth operation of
rolling resistance of frontal
the
continuous casting
rolling using theprocess.
two-roller is the smallest among the three rolling methods, followed by
horizontal rolling, then vertical rolling, which is the largest. This follows the same order as
the rolling force, and the rolling resistance difference for various rolling methods is very
small. The rolling resistance increases with the two-chamfered length. The excessive rolling
Metals 2022, 12, 1984 11 of 18

resistance will directly affect the stable and smooth operation of the continuous casting
Metals 2022, 12, 1984 process. 11 of 18

Table 2. Rolling resistance for different rolling methods. (ton).

Table 2. Rolling resistance
Chamfered for different
Length (mm) rolling methods. (ton).
11 14 17 20
Rolling MethodsChamfered Length (mm) 11 14 17 20
Rolling Methods
Horizontal rolling 5.9 7.9 11.2 18.6
Horizontal rolling 5.9 7.9 11.2 18.6
Vertical rolling 6.1 9.3 13.4 19.0
Vertical rolling 6.1 9.3 13.4 19.0
Frontal rolling using a two-roller 5.6 8.0 11.0 18.2
Frontal rolling using a two-roller 5.6 8.0 11.0 18.2

3.2.3. Influence of the Two-Chamfered Method on the Deformation of the Slab Corner
3.2.3. Influence of the Two-Chamfered Method on the Deformation of the Slab Corner
(1) Horizontal rolling
(1) Horizontal rolling
The
The metal
metal deformation
deformation atat the
the slab
slab corner
corner is
is very
very important
important for
for controlling
controlling the
the edge
edge
seam defect during the two-chamfered rolling process. Table 3 shows the
seam defect during the two-chamfered rolling process. Table 3 shows the slab corner slab corner
de-
deformation values when the two-chamfered lengths are 11 mm, 14 mm,
formation values when the two-chamfered lengths are 11 mm, 14 mm, 17 mm, and 20 mm 17 mm, and
20 mm under horizontal-rolling, respectively. The deformation value in the X direction (i.e.,
under horizontal-rolling, respectively. The deformation value in the X direction (i.e., the
the width direction) is positive to the right and negative to the left; the deformation in the
width direction) is positive to the right and negative to the left; the deformation in the Y
Y direction (i.e., the thickness direction) is positive upward and negative downward.
direction (i.e., the thickness direction) is positive upward and negative downward.
Table 3. Node deformation at different two-chamfered lengths under horizontal rolling (mm).
Table 3. Node deformation at different two-chamfered lengths under horizontal rolling (mm).
Two-Chamfered
Direction Two-Chamfered
A B Direction
C A D B Ca D b a bc c d d
Length(mm) Length(mm)
X −3.40 −0.10 X −0.01 −3.40 0.01
−0.10 −0.01
1.30 0.01 −0.01
1.30 −0.01
0.09 0.09 0.02 0.02
11 11
Y 1.68 0.12 Y 0.03 1.68 0.01 0.12 − 0.55 0.01 0.04
0.03 −0.55 − 0.004 −0.004 0.01
0.04 0.01
X −4.60 −0.70 X −0.12 −4.60−0.004
−0.70 1.40 −0.004 0.071.40
−0.12 0.09 0.09 0.03
0.07 0.03
14
Y 2.10 14 0.67 Y 0.09 2.10 0.01 0.67 − 0.70 0.01 0.01
0.09 −0.70 −0.02 −0.02 0.01
0.01 0.01
X −6.12 −1.90 X −0.77 −6.12 −0.01
−1.90 − 0.13
−0.77 −0.01 0.13
−0.13 0.07 0.07 0.03
0.13 0.03
17
Y 2.80 17 1.70 0.58 0.01 −0.80 0.01 −0.02 −0.004
Y 2.80 1.70 0.58 0.01 −0.80 0.01 −0.02 −0.004
X −7.90 −3.4 −1.8 −0.08 −1.63 0.16 0.08 0.05
X −7.90 −3.4 −1.8 −0.08 −1.63 0.16
−0.01 0.08 −0.004 0.05
20
Y 3.50 20 2.80 1.44 0.07 −0.96 −0.01
Y 3.50 2.80 1.44 0.07 −0.96 −0.01 −0.01 −0.004

Figure 12 shows the deformation of the corner under the typical working conditions
of horizontal rolling
rolling with
with aa chamfer
chamfer length
length of
of 20
20 mm.
mm.

Figure 12. Deformation

Deformationof
ofthe
theslab
slabcorners
cornersunder
underhorizontal
horizontalrolling with
rolling a chamfered
with length
a chamfered of 20
length of
mm.
20 mm.

Table 33 and
Table and Figure
Figure 10
10 show
show that
that the
the slab
slab is
is mainly
mainly deformed
deformed onon the wide face during
horizontal rolling. As the length of the
the two-chamfered
two-chamfered slope
slope increases,
increases, the
the displacement
displacement
of node-A to the left gradually increases in the X direction. The nodes A, B, C, and D are
compressed, and the displacement to the left is sequentially decreased. In the Y direction,
the upward bulge of node-A gradually increases, and the bulge of nodes A, B, C, and D
decreases in turn. When the length of the two-chamfered slope is 20 mm, the displacement
of node-A to the left reaches 7.9 mm, and the upward bulge of node-A reaches 3.5 mm. If
Metals 2022, 12, 1984 12 of 18

compressed, and the displacement to the left is sequentially decreased. In the Y direction,
Metals 2022, 12, 1984 the upward bulge of node-A gradually increases, and the bulge of nodes A, B, C,12and D
of 18
decreases in turn. When the length of the two-chamfered slope is 20 mm, the displacement
of node-A to the left reaches 7.9 mm, and the upward bulge of node-A reaches 3.5 mm. If
the length of the two-chamfered slope is further increased, the excessive protrusion on the
the length of the two-chamfered slope is further increased, the excessive protrusion on the
slab bottom face will cause scratches at node-A and affect the slab quality.
slab bottom face will cause scratches at node-A and affect the slab quality.
On the chamfered slope face, the deformation of node-a is the largest. Under the rolling
On the chamfered slope face, the deformation of node-a is the largest. Under the roll-
condition of the small two-chamfered length, node-a is not on the two-chamfered face, and
ing condition of the small two-chamfered length, node-a is not on the two-chamfered face,
node-a is convex in the X direction at this time. When the two-chamfered length increases
and node-a is convex in the X direction at this time. When the two-chamfered length in-
to 20 mm, the displacement of node-a appears as a compression to the left and down and
creases
turns ontothe
20two-chamfered
mm, the displacement of node-a
face. By contrast, appears
node-b ason
is not a compression to theface,
the two-chamfered left and
and
down and turns on the two-chamfered face. By contrast, node-b is not on the
the position of node-b is almost unchanged. The line segment between node-a and node-b two-cham-
fered face, and
is stretched andthe position of
lengthened, node-b
and is almost unchanged.
this deformation Theisline
characteristic verysegment
importantbetween
in the
node-a and node-b is stretched
subsequent stress analysis. and lengthened, and this deformation characteristic is very
important in the subsequent stress analysis.
(2) Vertical rolling
(2) Vertical rolling
Table 4 lists the slab corner deformation of nodes A, B, C, D and a, b, c, d when
Table 4 lists the slab corner deformation of nodes A, B, C, D and a, b, c, d when the
the two-chamfered length are 11 mm, 14 mm, 17 mm, and 20 mm under vertical rolling,
two-chamfered length are 11 mm, 14 mm, 17 mm, and 20 mm under vertical rolling, re-
respectively. Figure 13 shows the deformation of the corner under the typical working
spectively. Figure 13 shows the deformation of the corner under the typical working con-
conditions of vertical rolling with a chamfered length of 20 mm.
ditions of vertical rolling with a chamfered length of 20 mm.
Table 4. Node deformation at different two-chamfered lengths under vertical rolling (mm).
Table 4. Node deformation at different two-chamfered lengths under vertical rolling (mm).
Two-Chamfered
Direction Two-Chamfered
A B Direction
C A DB Ca D b a bc c d d
Length (mm) Length(mm)
X −1.67 0.04 X −0.04−1.67 0.02 0.04 3.11
−0.04 0.02 0.163.11 0.21
0.16 0.21 0.03
0.03
11 11
Y 1.22 0.04 Y 0.05 1.22 0.005 0.04 −1.55
0.05 0.005−0.006
−1.55 −0.05
−0.006 −0.05 0.003
0.003
X −2.10 0.13 X −0.13−2.10 0.01 0.13 3.50
−0.13 0.01 0.583.50 0.40
0.58 0.40 0.03
0.03
14
Y 1.7014 0.16 Y 0.10 1.70 0.004 0.16 −
0.102.1 0.004 −0.01
−2.1 − 0.16
−0.01 −0.16 −0.01
−0.01
X −2.30 0.01 −0.23 −0.004 3.90 1.57 1.03 0.10
17 X −2.30 0.01 −0.23 −0.004 3.90 1.57 1.03 0.10
Y 1.8017 0.28 0.15 0.02 −2.94 −0.33 −0.31 −0.02
Y 1.80 0.28 0.15 0.02 −2.94 −0.33 −0.31 −0.02
X −2.30 −0.5 −0.27 −0.04 4.32 3.50 1.82 0.34
20 X −2.30 −0.5 −0.27 −0.04 −1.00
4.32 3.50 1.82 0.34
Y 0.7420 1.00 0.20 0.05 −4.25 −0.54 −0.09
Y 0.74 1.00 0.20 0.05 −4.25 −1.00 −0.54 −0.09

Figure 13. Deformation

Deformationmorphology
morphologyofofthe slab
the corners
slab under
corners vertical
under rolling
vertical with
rolling a chamfered
with a chamfered
length of 20 mm.
length of 20 mm.

The slab is mainly deformed on the chamfered slope face during vertical rolling. The
bulge amount of node-a in the slab wide direction gradually increases with the increasing
of the two-chamfered length. When
When the
the length
length of
of the two-chamfered
two-chamfered face
face is 20 mm, the
bulge amount of node-a is very large and can reach 4.32 mm. NodesNodes a, b, c, and d are
sequentially compressed, and the bulge amount gradually decreases. The bulge amount
of node-a and node-b will increase when the length of the two-chamfered face further
increases. The bottom face may become the original source of new fold lines, which di-
rectly cause the occurrence of edge seam defects; and (2) the bulge at node-A is larger on
the wide face of the slab with a maximum bulge of 1.8 mm. Node-A is not on the two-
chamfered face and the deformation in the thickness direction appears to be gradually
Metals 2022, 12, 1984 13 of 18

increases. The bottom face may become the original source of new fold lines, which directly
Metals 2022, 12, 1984 cause the occurrence of edge seam defects; and (2) the bulge at node-A is larger on the13wide
of 18
face of the slab with a maximum bulge of 1.8 mm. Node-A is not on the two-chamfered
face and the deformation in the thickness direction appears to be gradually convex when
the two-chamfered length is rolled at 11 mm and 14 mm. When it increases to 17 mm and
convex when the two-chamfered length is rolled at 11 mm and 14 mm. When it increases
20 mm, node-A turns on the two-chamfered face and the deformation in the Y direction
to 17 mm and 20 mm, node-A turns on the two-chamfered face and the deformation in the
shows that the amount of bulging gradually decreases.
Y direction shows that the amount of bulging gradually decreases.
(3)
(3) Frontal
Frontalrolling
rollingusing
usingaatwo-roller
two-roller
For
Forfrontal
frontalrolling
rollingusing
usingaatwo-roller,
two-roller,although
althoughthe therolling
rollingisiscarried
carriedout
outalong
alongthe
the
bisector direction of the angle, the deformation of the slab’s wide face and
bisector direction of the angle, the deformation of the slab’s wide face and the chamfered the chamfered
face
faceisisnot
notconsistent,
consistent, asas
shown
shownin Table 5 and
in Table Figure
5 and 14. The
Figure deformation
14. The deformationon theonchamfered
the cham-
face
feredis face
slightly larger, larger,
is slightly which which
may bemay
caused by theby
be caused shorter lengthlength
the shorter of the of
chamfered face.
the chamfered
Nodes A, B, C, and D are compressed along the X direction under the frontal-rolling
face. Nodes A, B, C, and D are compressed along the X direction under the frontal-rolling with
awith
two-roller process.
a two-roller The maximum
process. The maximum bulge amount
bulge amountof node-A
of node-A is 2.3 mm
is 2.3 mm and
andisisnot
notonon
the
the two-chamfered face under small rolling conditions (i.e., when the rolling length is is
two-chamfered face under small rolling conditions (i.e., when the rolling length 11
11 mm,
mm, 1414mm,mm, andand17 17 mm).
mm). WhenWhenthe the chamfered
chamfered length
length increases
increases to 20tomm,
20 mm,
node-Anode-A
turns
turns
on theon two-chamfered
the two-chamfered faceface
andand
thethe bulge
bulge amountdecreases.
amount decreases.Nodes
Nodesa,a,b, b, c,
c, and
and ddare
are
pressed in the Y direction of the slab and the pressing amount gradually
pressed in the Y direction of the slab and the pressing amount gradually decreases on the decreases on the
chamfered
chamferedslope slopeface.
face. The reduction of
The reduction of each
each node
nodeincreases
increasesgradually
graduallywithwiththe
theincrease
increaseof
of the two-chamfered length. In the X direction, the bulge amount of node-a is the largest
the two-chamfered length. In the X direction, the bulge amount of node-a is the largest
compared with the original position. However, the range of bulging of node-a is very small
compared with the original position. However, the range of bulging of node-a is very
under the conditions of different two-chamfered rolling amounts, with a maximum value
small under the conditions of different two-chamfered rolling amounts, with a maximum
of 2.88 mm and a minimum value of 2.30 mm.
value of 2.88 mm and a minimum value of 2.30 mm.
Table 5. Node deformation of different two-chamfered lengths under frontal rolling using a two-
Table 5. Node deformation of different two-chamfered lengths under frontal rolling using a two-
roller (mm).
roller (mm).
Two-Chamfered
Direction Two-Chamfered
A B C
Direction A D B aC D b a bc c d d
Length (mm) Length(mm)
X −1.94 0.04 −
X 0.04 −1.940.02 0.04 2.30
−0.04 0.020.06 2.30 0.13
0.06 0.13 0.030.03
11 mm 11 mm
Y 1.19 0.04 Y0.04 1.190.01 0.04 −1.08
0.04 0.010.02 −1.08 −0.02
0.03 −0.03 0.010.01
X −2.6 0.03 −
X 0.07 −2.60.01 0.03 2.88
−0.07 0.010.06 2.88 0.18
0.06 0.18 0.010.01
14 mm
Y 1.5014 mm 0.06 Y0.05 1.500.01 0.06 −1.58
0.05 −0.01−1.58
0.01 − 0.06
−0.01 −0.06−0.01
−0.01
X −3.2 −0.04 −0.39 −0.003 2.57 0.92 0.59 0.05
17 mm X −3.2 −0.04 −0.39 −0.003 2.57 0.92 0.59 0.05
Y 2.3017 mm 0.45 0.25 0.016 −2.11 −0.04 −0.16 −0.01
Y 2.30 0.45 0.25 0.016 −2.11 −0.04 −0.16 −0.01
X −3.79 −0.93 −0.44 −0.02 2.66 2.0 0.99 0.10
20 mm X0.31 −3.79 −0.93 −0.44 −0.02
Y 2.0920 mm 1.16 0.04 −2.70 −0.362.66 −2.0
0.27 0.99−0.020.10
Y 2.09 1.16 0.31 0.04 −2.70 −0.36 −0.27 −0.02

Figure14.
Figure 14.Deformation
Deformationmorphology
morphologyofofthe
theslab
slabcorners
cornersunder
underfrontal
frontalrolling
rollingusing
usingaatwo-roller
two-rollerwith
with
aachamfered
chamferedlength
lengthofof2020mm.
mm.

Comprehensively comparing and analyzing the effects of the three kinds of two-
chamfered methods on the corner shape and the bulge amount in X and Y directions, it
can be concluded that horizontal rolling is likely to cause large amounts of bulging on the
slab’s wide face, and vertical rolling is prone to cause a large amount of bulging on the
chamfered slope face. The bulge amount of both the wide face and the chamfered slope
 Metals 2022, 12, 1984 14 of 18

Comprehensively comparing and analyzing the effects of the three kinds of two-
022, 12, 1984 14 of 18
chamfered methods on the corner shape and the bulge amount in X and Y directions, it
can be concluded that horizontal rolling is likely to cause large amounts of bulging on the
slab’s wide face, and vertical rolling is prone to cause a large amount of bulging on the
face is relatively small under
chamfered slopethe frontal
face. The bulgerolling usingofa both
amount two-roller,
the wide which can the
face and meet the
chamfered slope face
needs of the two-chamfered
is relatively smallshape and the
under the frontal
production process.
rolling using a two-roller, which can meet the needs of
the two-chamfered shape and the production process.
3.2.4. Stress Distribution at the Slab Corner during the Two-Chamfered Process
3.2.4. Stress Distribution at the Slab Corner during the Two-Chamfered Process
Figure 15 shows the process of change for stress at the slab corner from the start to
the end of rolling under Figure 15 shows
horizontal the process
rolling, verticalofrolling,
changeand for frontal
stress at the slab
rolling corner
using a two-from the start to
roller, respectively. The slab is subjected to compressive stress on the contact surface be-rolling using a
the end of rolling under horizontal rolling, vertical rolling, and frontal
tween the roller two-roller, respectively.
and the slab during the Thehorizontal
slab is subjected
rolling to compressive
process. On thestress
otheronhand,
the contact surface
there is a tensile stress zone and the maximum tensile stress reaches 248.8 MPa at thethe other hand,
between the roller and the slab during the horizontal rolling process. On
lower part of the there is a tensile stress
two-chamfered zone
surface. It and the maximum
is caused tensile stress
by the extrusion of the reaches
chamfered 248.8 MPa at the
lower part of the two-chamfered surface. It is caused
surface from the side of the roller during the horizontal-rolling process. The distribution by the extrusion of the chamfered
of extrusion deformation is different. The extrusion deformation of the wide face near the distribution of
surface from the side of the roller during the horizontal-rolling process. The
top of the slab extrusion
is large and deformation is different.
the lower edge The extrusion deformation
of the two-chamfered face is small, of which
the widepro-face near the top
of the slab is large and the lower edge of the two-chamfered
motes the formation of tensile stress there. Especially when the two-chamfered length is face is small, which promotes
great (20 mm), node-a is already on the two-chamfered face, which shows a leftward com-length is great
the formation of tensile stress there. Especially when the two-chamfered
(20 mm), node-a is already on the two-chamfered face, which shows a leftward compression
pression along the width direction. However, the position of node-b is almost unchanged,
along the width direction. However, the position of node-b is almost unchanged, which
which results in the line segment between node-a and node-b increasing and creates ten-
results in the line segment between node-a and node-b increasing and creates tensile stress.
sile stress. It is perhaps for this reason that the transverse cracks on the slab surface oc-
It is perhaps for this reason that the transverse cracks on the slab surface occurred.
curred.

(a) (b)

(c)
Figure 15. StressFigure
on a slab
15. corner
Stress under two-chamfered
on a slab corner under rolling process. (a)rolling
two-chamfered Horizontal rolling;
process. (a) (b)
Horizontal rolling;
vertical rolling; (c) frontal rolling using a two-roller.
(b) vertical rolling; (c) frontal rolling using a two-roller.

The slab is subjected

The slab to is
compressive
subjected tostress on the contact
compressive surface
stress on between
the contact the roller
surface between the roller
and the slab during
and thethe vertical
slab during rolling process,rolling
the vertical whichprocess,
is similar to horizontal
which is similarrolling.
to horizontal rolling.
However, thereHowever,
is a tensile stress
there is azone and
tensile the maximum
stress zone and thetensile stress tensile
maximum reachesstress
173.3reaches
MPa 173.3 MPa at
at the upper part of the two-chamfered surface. It is caused by the extrusion of the cham-
the upper part of the two-chamfered surface. It is caused by the extrusion of the chamfered
fered face from the top face of the roll during the vertical rolling process. The distribution
of the extrusion deformation is different. The lower edge of the two-chamfered face has
the largest extrusion deformation. The extrusion deformation of the wide face on the slab
top is the smallest, which promotes the formation of tensile stress there. The formation
 Metals 2022, 12, 1984 15 of 18

Metals 2022, 12, 1984 face from the top face of the roll during the vertical rolling process. The distribution of
15 of 18
Metals 2022, 12, 1984 the extrusion deformation is different. The lower edge of the two-chamfered 15 face
of 18has the

largest extrusion deformation. The extrusion deformation of the wide face on the slab
top is the smallest, which promotes the formation of tensile stress there. The formation
mechanism of this tensile stress zone is the same as that for horizontal rolling, only the
mechanism
mechanism of this of this tensile
tensile stressiszone
stress zone is theas
the same same
thatas
forthat for horizontal
horizontal rolling,rolling,
only the only the
stress value is smaller.
stress value is
stress value is smaller. smaller.
The rollers are flat and the movement speed of each point on the surface of the rolls
The rollers
The rollers are flatare
andflatthe
and the movement
movement speedspeed of point
of each each point
on theonsurface
the surface
of theofrolls
the rolls is
is the same during frontal rolling using a two-roller. The rollers are rolled along the bisec-
the same
is the same duringduring frontal
frontal rolling rolling
usingusing a two-roller.
a two-roller. The rollers
The rollers are rolled
are rolled alongalong the bisector
the bisec-
tor of the slab angle between the wide face and the chamfered slope, which leads to the
of the
tor of the slabslab angle
angle between
between thethewide
widefacefaceand
andthe
thechamfered
chamfered slope,
slope, which leads
leadsto tothe
thecontact
contact between the rollers and the slab faces are all subjected to compressive stress.
contactbetween
betweenthe therollers
rollersand andthethe
slab faces
slab areare
faces all subjected to compressive
all subjected stress.
to compressive Therefore,
stress.
Therefore, there is no tensile stress near the two-chamfered face. This is favorable for the
therethere
Therefore, is noistensile stress
no tensile nearnear
stress the two-chamfered
the two-chamfered face.face.
ThisThis
is favorable for the
is favorable quality of
for the
quality of the two-chamfered slab.
the two-chamfered slab.
quality of the two-chamfered slab.
3.3.
3.3.Industrial
Industrial Applications
Applications ofofTwo-Chamfered
Two-Chamfered Technology
Technology
3.3. Industrial Applications of Two-Chamfered Technology
AAlarge number of industrial productions
large number of industrial productions have havebeen
beencarried
carried out
out with
with thethe two-cham-
two-chamfered
A large number of industrial productions have been carried out with the two-cham-
fered
equipment for slabs. Figure 16 shows the industrial application of the horizontalhorizontal
equipment for slabs. Figure 16 shows the industrial application of the rolling and
fered equipment for slabs. Figure 16 shows the industrial application of the horizontal
rolling
frontaland frontal
rolling with rolling with a two-roller.
a two-roller. It is carriedItout
is carried
on the out on the single-strand
single-strand large slab
large slab continuous
rolling and frontal rolling with a two-roller. It is carried out on the single-strand large slab
continuous caster
caster for the for the production
production of a slab with of a260
slabmm with 260 mmand
thickness thickness and 1500–2500
1500–2500 mm width.mm The
continuous caster for the production of a slab with 260 mm thickness and 1500–2500 mm
width. The production
production trials showtrials
that ifshow that if of
the length thethelength of the two-chamfered
two-chamfered face is in
face is controlled con-
the
width. The production trials show that if the length of the two-chamfered face is con-
trolled in 14
range of thetorange
20 mm, of the
14 shape
to 20 mm,of thethe shape of the slab
two-chamfered two-chamfered
can meet theslab can meet for
requirements thea
trolled in the range of 14 to 20 mm, the shape of the two-chamfered slab can meet the
requirements for a subsequent
subsequent rolling of heavy platesrollingas of heavy
shown inplates
Figureas17.
shown in Figure cylinder
The hydraulic 17. The hydrau-
pressure
requirements for a subsequent rolling of heavy plates as shown in Figure 17. The hydrau-
lic
ofcylinder pressure
the chamfering of the
roller chamfering
is about 60–70 roller
MPa andis about 60–70current
the input MPa and theCCM
of the inputwithdrawal
current of
lic cylinder pressure of the chamfering roller is about 60–70 MPa and the input current of
the CCMiswithdrawal
system increased bysystem is increased
about 30–40 amperesbywhen
aboutthe30–40 amperes when
two-chamfered the of
length two-cham-
the slab is
the CCM withdrawal system is increased by about 30–40 amperes when the two-cham-
fered
aboutlength
17 mm. of the slab is about 17 mm.
fered length of the slab is about 17 mm.

(a) (b)
(a) (b)
Figure
Figure16.
16.Industrial
Industrialapplications
applicationsofoftwo-chamfered
two-chamferedequipment.
equipment.(a)
(a)Horizontal
Horizontalrolling;
rolling;(b)
(b)frontal
frontal
Figurerolling
16. Industrial
with a applications of two-chamfered equipment. (a) Horizontal rolling; (b) frontal
two-roller.
rolling with a two-roller.
rolling with a two-roller.

(a) (b)
(a) (b)
Figure 17. A two-chamfered shape slab. (a) Hot slab; (b) cold slab.
Figure 17. A two-chamfered
Figure shape slab.
17. A two-chamfered shape(a)slab.
Hot (a)
slab;
Hot(b)slab;
cold(b)
slab.
cold slab.
The two-chamfered slab produced by the above two kinds of equipment were rolled
The two-chamfered slab produced by the above two kinds of equipment were rolled
and the rolling broadside ratio was 1.5–2.73. The edge seam defects are obviously im-
and the rolling broadside ratio was 1.5–2.73. The edge seam defects are obviously im-
proved by the application of rolling a two-chamfered slab compared with the right-angle
proved by the application of rolling a two-chamfered slab compared with the right-angle
slab. The frontal rolling with a two-roller can meet the needs of controlling edge seam
slab. The frontal rolling with a two-roller can meet the needs of controlling edge seam
defects under large broadside ratio rolling, which is better than the horizontal rolling. The
defects under large broadside ratio rolling, which is better than the horizontal rolling. The
Metals 2022, 12, 1984 16 of 18

Metals 2022, 12, 1984 The two-chamfered slab produced by the above two kinds of equipment were16rolled of 18
Metals 2022, 12, 1984 and the rolling broadside ratio was 1.5–2.73. The edge seam defects are obviously improved 16 of 18
by the application of rolling a two-chamfered slab compared with the right-angle slab.
The frontal
frontal rolling
rolling with
using a two-roller
a two-roller can meet
is applied forthe
theneeds of controlling
slab with edge seamand
250 mm thickness defects
1650
under
frontal
mm large
width broadside
rolling
whichusing ratio
is arolled rolling,
two-roller which
into aisheavy is
applied better
for with
plate than
the slab the horizontal
withmm
16–21 250thicknessrolling.
mm thickness The frontal
and
and 4500 1650
mm
rolling
mm using
width a two-roller
which is is
rolled applied
into a for the
heavy slab
platewith
with250 mm
16–21 thickness
mm and
thickness
width. Figure 18 shows the typical edge seam defect of heavy plates produced from a two- 1650
and mm4500width
mm
which
width. isFigure
rolled18 into a heavy
shows the plate with
typical edge16–21
seam mm thickness
defect of heavyand 4500 produced
plates mm width.from Figure
a 18
two-
chamfered slab undergoing frontal rolling with a two-roller. The edge seam defect ratio is
shows the typical
chamfered slab edge seamfrontal
undergoing defect rolling
of heavywithplates
a producedThe
two-roller. from a two-chamfered
edge seam defect slabis
ratio
less than 5%. Even if the edge seam defect appears occasionally, its position is within 10
undergoing
less than frontal
Even rolling withseam
a two-roller. The edge seam defect its ratio is less than 5%.
mm from 5%.
the edge, if
andtheits
edge defect
shape is finer andappears
smaller occasionally,
than that produced positionfromis the
within 10
right-
Even if
mm from the edge seam defect appears occasionally, its position is within 10 mm from the
angle slab.the edge, and its shape is finer and smaller than that produced from the right-
edge,
angleand
slab.its shape is finer and smaller than that produced from the right-angle slab.

Figure 18. Typical morphology of an edge seam defect on heavy plates produced by the two-cham-
Figure
fered
Figure 18.under
slab
18. Typical morphology
frontal
Typical ofofanan
rolling with
morphology aedge seam
two-roller.
edge defect
seam on heavy
defect plates
on heavy produced
plates by thebytwo-cham-
produced the two-
fered slab under
chamfered frontal
slab under rolling
frontal withwith
rolling a two-roller.
a two-roller.
Figure 19 shows the two-chamfered slab produced using horizontal-rolling equip-
ment. Figure
Figure 1919shows
shows
Occasionally, the
the
there two-chamfered
two-chamfered
are very smallslab slab produced
produced
cracks on theusing using horizontal-rolling
horizontal-rolling
two-chamfered equip-
equipment.
face caused by the
ment. Occasionally,
Occasionally, there are there
very are very
small small
cracks on cracks
the on the
two-chamferedtwo-chamfered
face caused
extrusion of the wheel rim of the horizontal rolling. These small cracks lead to the occur-face
by caused
the by the
extrusion
extrusion
of the of
wheel the
rim wheel
of the rim of the
horizontal horizontal
rolling. rolling.
These small These
cracks small
lead cracks
rence of the edge seam defect 30–40 mm away on the heavy plate. Therefore, it can beto the lead to the
occurrence occur-
of the
renceseam
edge of the
concluded edge
defect
that the seam
30–40
frontaldefect
mm away30–40
rolling mm
on the
with awayplate.
heavy
a two-roller on isthe heavy
Therefore,
the plate.
optimum it canTherefore,
for be it can
theconcluded
application be
that
of
concluded
the that
frontal rolling
two-chamfered the frontal rolling
with a two-roller
technology, with a
is the
confirmed two-roller
byoptimum is the
industrialfortrials optimum
the application for
and numerical the application
of two-chamfered
simulation re- of
two-chamfered
technology,
sults. technology,
confirmed confirmed
by industrial trialsbyand
industrial
numerical trials and numerical
simulation results. simulation re-
sults.

Figure 19.
Figure 19. Small
Small cracks
cracks on
on the
the slope
slope face
face of
of aa two-chamfered
two-chamfered slab
slab under
under horizontal
horizontalrolling.
rolling.
Figure 19. Small cracks on the slope face of a two-chamfered slab under horizontal rolling.
4.
4. Conclusions
Conclusions
4.
(1) Conclusions
Compared with with the
the right-angle
right-angle slabslab and
(1) Compared and the
the one-chamfered
one-chamfered slab,
slab, the
the two-chamfered
two-chamfered
(1) slab
Compared
slab has a with
higher the right-angle
corner temperatureslab and
and the one-chamfered
uniformity, which
has a higher corner temperature and uniformity, which is beneficial slab,
is the two-chamfered
beneficial to to
thethe
defor-
de-
mation
slab has during
a the
higher rolling
corner process.
temperature
formation during the rolling process. and uniformity, which is beneficial to the de-
(2) The rolling
formation force
during required
the for
rolling two-chamfered
process. rolling by frontal rolling
(2) The rolling force required for two-chamfered rolling by frontal rolling using a two- using a two-
roller
(2) roller is the
the smallest
The rolling
is smallest amongfor
force required
among thetwo-chamfered
the three rolling
three rolling methods,
methods, followed
rolling followed
by by
frontalby horizontal
rolling rolling,
usingrolling,
horizontal a two-
with
with vertical
rollervertical rolling
is the smallest requiring
among the
rolling requiring the largest
three
the amount.
rolling
largest The
methods,
amount. rolling
followed
The rolling resistance to the
by horizontal
resistance casting
rolling,
to the casting
with vertical
machine showsrolling requiring
the same theSuitable
results. largest amount. The rolling resistance
corner deformation to the casting
of two-chamfered slab
machine shows the same results. Suitable corner
can be obtained using frontal rolling with a two-roller. deformation of two-chamfered slab
can be obtained using frontal rolling with a two-roller.
Metals 2022, 12, 1984 17 of 18

machine shows the same results. Suitable corner deformation of two-chamfered slab
can be obtained using frontal rolling with a two-roller.
(3) The slab with a favorable two-chamfered shape can be produced by frontal rolling with
a two-roller at the optimized chamfered length. The two-chamfered slab produced
by the frontal rolling of two-roller equipment can make the edge seam defect ratio
on heavy plates less than 5%, even under the conditions of a large broadside ratio,
and the position of the edge seam defect occurs within 10 mm from the edge of the
heavy plate.

Author Contributions: Conceptualization, M.W. and H.Z.; methodology, M.W., H.Z., H.L. and W.Z.;
software, W.Z., H.L. and X.W.; writing—original draft preparation, M.W., H.Z. and H.L.; writing—
review and editing, M.W. and H.L. All authors have read and agreed to the published version of
the manuscript.
Funding: This research was funded by National key R&D project of China (No. 2017YFB0304004).
Institutional Review Board Statement: Not applicable.
Informed Consent Statement: Not applicable.
Data Availability Statement: Not applicable.
Conflicts of Interest: The authors declare no conflict of interest.

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